High Performance Frying 2016 - Food Service Technology Center · It’s All About Fry Cost per Day • Commodity Oil Cost per Day – $25 case * 4 cases = $100 – $100/5 days of

© 2016 Fisher-Nickel, inc.

High Performance FryingGet the Most Out of

Your Fryer OperationPresented by:

F S T C W o r k f o r c e E d u c a t i o n & T r a i n i n g

Todd Bell Sr Energy Analyst

Mark FinckSr. Engineer

Mission Critical Support by:

Kiana CabanCommunications Asst.

Janel RuppEd & Training Mgr

Andre HookfinLab Technician ll

Jenny Ritchie Event Asst.

Today’s Fantastic Guest Speaker:

Danny KlauerStratus Foods

Foodservice Region Manager916.769.7937

[email protected]


Download today’s presentation:

www.fishnick.com/handouts/04262016

The Food Service Technology Center (FSTC) program is funded by utility customers through the public purpose program and administered by the Pacific Gas and Electric Company under the auspices of the California Public Utilities Commission.

Fisher‐Nickel Inc. has managed the FSTC for PG&E since 1986.

Our Mission:

Promote Energy Efficiency in Commercial Food Service


Energy Audits

Appliance Testing Seminars

Faci l i ty Design

Fishnick.com


Rigorous Standard Test Methods are the Basis for Real Performance Comparison!

The FSTC’s Foundation is Appliance Testing

Test Data makesEnergy Star and Utility Rebates

possible!


It’s All About Energy To Food!

Efficiency = = %


Gas Fryer Efficiencies

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Improvements Over Time!

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Calculating Appliance Energy CostsAre Efficient Fryers worth the

Investment?

Acquisition Cost

Sustainability Cost

Energy WaterMaintenance


Let’s open the FSTC Online Toolbox


Annual Operating Cost Savings: $640 ROI: 3.4 yearsLifetime Cost Savings: $2,273ROI with CA Energy Wise Rebate: 2.3 years

Location: Chow, Danville Measured Energy Use

Hotline LocationMainlineOld Fryer (heavy use)

Mainline NEW Vulcan VK45

Fryer (heavy use)

Grill line Old Fryer (light use)

Grill line NEW Pitco VF35 Fryer

(light use)

Daily Energy Use (therms)

3.6 1.3 2.8 1.6

Annual EnergyUse (therms)

1,287 452 990 573

Annual Operating Cost Savings ($) $835* $417*

*Operating cost savings based on a natural gas utility rate of $1.00/therm.

PG&E Fryer Replacement Case Study

Main line Fryer Grill line Fryer


If you had to gas up your fryer every morning, your perspective would

quickly change…

Beyond EnergySelecting, Using and Maintaining the

Fryer and Oil

The Fryer ?’s1. Food Product2. Fryer Size3. Fryer Type

The Oil ?’s1. Food Product2. Food/Oil Interface3. Condition Over

Time4. Filtering5. Disposal


Food Product• French Fries• Onion Rings• Chicken• Fish• Cheese Sticks• Doughnuts• Vegetables• Twinkies• Etc!

Is it . . . o Frozen o Slackedo Fresho Breadedo Batteredo Nitrogen Frozen!

What is being Fried?Field Study Confirms the Obvious!


French Fry Types

Wild Variation in what comes out of the bag!

Thin cut, full skin frozen friesThin cut, full skin frozen fries

Effecting:Cook time, holding time, serving temperature and amount of debris in oil


Fryer Type• Gas or Electric• Open Vat• Tube• Flat Bottom• Pressure• Floor• Countertop

Does it have . . .o a timero oil temperature displayo controls that adjust cook

time based on oil temp

Gas vs. Electric Fryers• electric appliance typically 1.5 to 3 times more efficient

• electricity costs 2.5 to 4 times more per unit of energy

• gas appliances typically less expensive to operate in California

Heating Element

Heat Exchanger

Electric Fryer Natural Gas Fryer


Electric FryersThe heating element in the cooking oil

Gas Fryer Types &Heat Exchangers

Side Heat Tube Heat Flat Bottom


Gas Side Heat / Open Vat Fryer

Oil level critical for adequate product coverage!

Collection Zone

Tube Heat Fryer

Collection Zone


Advance Tube Heat Exchanger DesignsMore surface area = More heat to oil!

Cooking Energy Efficiency: 65%+

Vulcan Multi Pass Heat Exchanger


Cleaning Considerations

Carbon cleaner High temperature brushes

Don’t Forget Behind the Door!

• Fuel to BURN

FIRE HAZARD!


Controlling the Fryer

• Lower cost models control oil temperature only

• Mechanical thermostat – No confirmation of Oil operating temper; large temperature swings

• Computer control thermostat = display with temperature readout; better temperature accuracy

• Computer with cooking time recipe and error messages of fry condition

Courtesy of Pitco


Thermostats

• Poorly maintained relays and thermostats can fail*

• Controls (high limit switches) can easily be overridden

• Sensor Breakage come failure

• Knobs often missing

Controls Solid‐state “Computer Control”


Fryer selected, now you need to fill it!

HIGH PERFORMANCE FRYING

All Oils are NOT Created Equal

Danny Klauer – Foodservice Region Manager


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• Beans are crushed to make meal and crude oil.

• Crude oil is refined, bleached, and deodorized to make salad oil.

• Salad oil is the beginning of the edible oil array.

• Frying oil is made by adding TBHQ and silicone to salad oil

From the Bean to the Box…Oil Processing

• Soy ‐ grassy, bean‐like

• Corn ‐ bland, chippy

• Peanut ‐ nutty, wood‐like

• Canola ‐ bland, grassy

• Cottonseed ‐ smooth, clean

• Sun ‐ bland, pine‐like

Different oils have different flavors...

…and flavor makes a difference!


Trans Fats

Where does trans fat come from?

• Most of the trans fat in food products comes from hydrogenated vegetable oils.

• Hydrogenation is the process of reacting hydrogen gas with oil to create solid or pliable shortenings.

• One of the results of hydrogenation is the formation of trans fat.

• A “Fully” Hydrogenated oil is a Saturated Fat

• “Fully” Hydrogenated oil does NOT contain trans fat

• “Partially” Hydrogenated oil contains Trans Fat

Frying Oils – Zero Trans

• Some operators believe the creamy liquid affects product mouth-feel and “finish”.

• Breading will have a dry, “matte” look versus a shiny, oily look.

• A matter of operator preference.

• To make a zero-trans creamy liquid, Stratas adds fully hydrogenated oil.

• Fully hydrogenated oils DO NOT contain trans fat.

Creamy Versus Clear


Each oil has a unique fatty acid profile – almost like a fingerprint

Fatty Acid Composition

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High Oleic Frying Oils vs CommodityFry Study Day 1

High Oleic Frying Oils vs CommodityFry Study Day 18


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THE SWEET SPOT


It’s All About Fry Cost per Day

• Commodity Oil Cost per Day

– $25 case * 4 cases = $100

– $100/5 days of life = $20 fry cost per day

• Premium Oil Cost per Day

– $40 case * 4 cases = $160

– $160/10 days of life = $16 fry cost per day

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SINGLE

CASE COST 1 2 3 4 5 6 7 8 9 10

$19.65 $19.65 $9.83 $6.55 $4.91 $3.93 $3.28 $2.81 $2.46 $2.18 $1.97

$20.00 $20.00 $10.00 $6.67 $5.00 $4.00 $3.33 $2.86 $2.50 $2.22 $2.00

$20.35 $20.35 $10.18 $6.78 $5.09 $4.07 $3.39 $2.91 $2.54 $2.26 $2.04

$20.70 $20.70 $10.35 $6.90 $5.18 $4.14 $3.45 $2.96 $2.59 $2.30 $2.07

$21.05 $21.05 $10.53 $7.02 $5.26 $4.21 $3.51 $3.01 $2.63 $2.34 $2.11

$21.40 $21.40 $10.70 $7.13 $5.35 $4.28 $3.57 $3.06 $2.68 $2.38 $2.14

$21.75 $21.75 $10.88 $7.25 $5.44 $4.35 $3.63 $3.11 $2.72 $2.42 $2.18

$22.10 $22.10 $11.05 $7.37 $5.53 $4.42 $3.68 $3.16 $2.76 $2.46 $2.21

$22.45 $22.45 $11.23 $7.48 $5.61 $4.49 $3.74 $3.21 $2.81 $2.49 $2.25

$22.80 $22.80 $11.40 $7.60 $5.70 $4.56 $3.80 $3.26 $2.85 $2.53 $2.28

SINGLE

CASE COST 1 2 3 4 5 6 7 8 9 10

$39.25 $39.25 $19.63 $13.08 $9.81 $7.85 $6.54 $5.61 $4.91 $4.36 $3.93

$39.60 $39.60 $19.80 $13.20 $9.90 $7.92 $6.60 $5.66 $4.95 $4.40 $3.96

$39.95 $39.95 $19.98 $13.32 $9.99 $7.99 $6.66 $5.71 $4.99 $4.44 $4.00

$40.30 $40.30 $20.15 $13.43 $10.08 $8.06 $6.72 $5.76 $5.04 $4.48 $4.03

$40.65 $40.65 $20.33 $13.55 $10.16 $8.13 $6.78 $5.81 $5.08 $4.52 $4.07

$41.00 $41.00 $20.50 $13.67 $10.25 $8.20 $6.83 $5.86 $5.13 $4.56 $4.10

$41.35 $41.35 $20.68 $13.78 $10.34 $8.27 $6.89 $5.91 $5.17 $4.59 $4.14

$41.70 $41.70 $20.85 $13.90 $10.43 $8.34 $6.95 $5.96 $5.21 $4.63 $4.17

$42.05 $42.05 $21.03 $14.02 $10.51 $8.41 $7.01 $6.01 $5.26 $4.67 $4.21

$42.40 $42.40 $21.20 $14.13 $10.60 $8.48 $7.07 $6.06 $5.30 $4.71 $4.24

COMMODITY OIL

BRILLIANCE OIL

OIL COST BASED ON NUMBER OF DAYS USED


CHAWS

Five key things shorten oil life - CHAWS: Carbon, Heat, Air, Water, Salt

• Set the thermostat to 350º.

• Periodically check the oil temperature with a thermometer to make sure the thermostat is accurate.

• Fry frozen foods frozen. Do not allow them to thaw before frying. Remove excess ice crystals.

• Never fill the baskets more than half full regardless of the food item.

• Skim floating particles from the fryer periodically.

• Never salt or season food items over the fryer, it will destroy the oil.

• During slack periods, turn the thermostat down to 200º

• Keep fryer kettles covered when not in use.

• Keep fryer kettles and baskets clean. Do not wash is dish machine.

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Testing

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• Polar compounds are impurities that develop in the oil as it breaks down• Europe uses total polars as their

benchmark measure of when to discard oil. The US is increasing its use of polars

also


Let’s cook some fries!

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Walk‐in Freezer Reach‐in Freezer Local Freezer Fryer DumpStation/Holding

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Fry Temperature (°F)

The Fry’s Excellent Adventure!


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Preparation

Measuring out the basket load size

Load size controlled


Walk‐in or Reach‐in Freezer Storage & Staging

Reach‐ins have temperature

stratification & fluctuations

Walk‐in Freezer

Automatized Fry Dispenser

Freezer with proportion control dispenser


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Frying

Filling the fry basket

Best Practice = fill basket outside the vat!


Fry Cook Time & Oil Temp Recovery

Standard Capacity Fryer Oil Temperature Profile

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Oil Temperature (°F)

Time (min)

Fries placed in Oil

Fries removed

Fryer recovered

“Slow” Recovery Time!

Cook time: 3:00

Recovery time: 1:09


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Oil Temperature (°F)

Time (min)

Fries placed in Oil

Fries removed

Fryer recovered

Near “Zero” Recovery Time!

High Capacity FryerOil Temperature Profile

Cook time: 2:12 Recovery time: 00:12

Gas Fryer Production Capacity

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Low Capacity

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When is the Fry Done?

Good internal texture

Still good visual appeal

When is the Fry Overcooked?

but, no moisture = potato chip

Still good visualappeal


When do you change your oil?

Oil Color ‐ Quality


Optimal Frying Range

The Oil Life Dilemma

Oil Life / Oil and Food Quality Tradeoff

Replace too Early

Increased Oil Cost

Replace too Late

Poor Food Quality

Ideal Replacement


Cone Filtering (China Cap)• Inexpensive and requires little storage space• Manual operation, messy, and safety concern

Portable Filters• Versatile, capable of multiple fryer application,

reversible• Proper sizing for fryer important• Requires storage space, safety concern over free

return hose

Built-In Filtration• Convenient, easy to use• Safe, hands-off operation• Readily available• No extra storage space required

Filtering Helps Extend Oil Life!

Filtering passing oil through a particle removing media

Metal mesh screens – larger holes to smaller – finer mesh Filter papers – 5 micron removal


New Oil 5 Days no filtration 5 Days Filtering Each Day

Built‐in Filtration is the Best Option


Low Oil Volume Fryers

Built in filtration & auto refill!

Oil Conserving Fryers40% Less Oil, 10% Less Energy, Outstanding Performance

Standard fryer needs:• 50 lbs. of oil• 26.5 liters/22.7 kg

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Low volume fryer needs:• 30 lbs. of oil• 14 liters/13.6 kg

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Safety

SAFETY


End of Cooking Oils have:Dollar Value

Reality of real world oil waist

Safe method of transporting used oil

Used oil transport caddyTransfer of disposable oil, tank in upright position

Unit lays on back to fill from fryer

Can be Safety Risk when transporting HOT oil. If the unit is dropped during transport hot oil can splash forward and exit fill / drain.


Oil Management Simplified

Frying Must Do’s

• Specify Energy Star & CA Energy Wise Fryers

• Match the vat to the food product being cooked

• Know your cook times and oil temp

• Protect the oil – CHAW on!

• Filter frequently with a filter cart or better yet spec’ a fryer with built in filtration

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Documents

High Performance Frying 2016 - Food Service Technology Center · It’s All About Fry Cost per Day • Commodity Oil Cost per Day – $25 case * 4 cases = $100 – $100/5 days of